Atlas Copco PBE 6 S Setup guide

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Special Tools

Required

■

Torx screwdriver TX 30 4932 319 998

■

Forcing disks 4931 599 018

■

Pulling-off device 9170 314 440

■

Adjustment tool for carbon brushes 9170 302 270

Important!

■

Before beginning the maintenance work, perform an initial check with a high voltage test according

to VDE (see chapter Electrical and Mechanical Test Instructions).

■

Before all repair work, pull the power plug from the socket!

■

Vor der Demontage ist das Gerät an den RTR-READER (Wartungsmeßgerät) anzuschließen, um einen

evtl. Wartungsintervall abzufragen.

Disassembly

Removing the

auxiliary handle

Unscrew the nut (2) and remove the

washer (3).

Pull out the screw (6).

☞

Press the clamping ring (1) and re-

move the auxiliary handle (4). Release

the tension and remove the clamping

ring (1).

Push back the rubber sleeve (A) and lever

off the rubber bushing (5).

Remove the rubber sleeve (A).

Remove the locking ring (9) with aid of cut

special pliers. If necessary, use a screw-

driver for support.

Remove the damping element (8) and the

damper (7).

Disassembling

the ball holding

device

Remove all four balls (1) with aid of a

magnet.

Loosen the five screws (B) of the adapter

sleeve (2) and remove the adapter

sleeve (2) as well as the O-ring (3). If nec-

essary, hit it lightly with a plastic hammer.

Remove the tool acceptance (4) com-

pletely with the snap die (A), the

spacer (5) and the gasket (6).

Remove the snap die (A) from the tool ac-

ceptance (4).

Remove the O-ring (9), the spacer (8), as

well as the recoil ring (7).

8 7

A 9

1 2 3

456

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Detaching the

carbon brushes

Loosen the screws (1) and remove the

brush covers (2).

Lift the brush springs (5) off the respective

carbon brushes (3) and place them on the

upper edge of the brush holders (4).

Pullbothcablelugs(handi)offthecarbon

brushes (3) and remove them.

Dismantling the

handgrip

Loosen the two screws (G) of the hous-

ing

(F).

Remove the handle screw (E) by steady-

ing the knurled nut (5) at the same time.

Remove the knurled nut (5).

Loosen the screw (B) and lever off the

handle cover (A) from below (it is not pos-

sible to lever off the handle cover from

above without destroying it!).

Unscrew the four screws (6) from the right

half of the handle (7).

Unscrew both Torx screws (8) TX 30 of

the handgrip holder (4) and remove them.

Pull off the handle shells completely with

the housing (F).

Remove the damping element (2).

☞

Attention: Do under no circumstances

further dismantle the damping ele-

ment!

Disconnect the plug-in connection (1) be-

tween the motor and the pair of handle

shells.

Remove the handgrip holder (4) and the

rubber collar (3) from the handle shells.

Remove the left handle shell (C) with the

holding-down device.

Loosen the cable clamps (D) and lay bare

the connecting cable (H) with the cable

entry sleeve.

Remove the switch (9) with the capacitor

from the handle shell.

A B

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Detaching the

armature

Loosen the two short (A) and the two

long (D) screws.

Remove the motor housing (9) with the

field (1) and the air deflector ring (2).

Remove the air deflector ring (2) from the

motor housing (9) and expel the field (1)

from the motor housing (9).

Loosenthe screws (B).Remove the brush

holders (C) from the motor housing (9).

Pull out the complete armature by turning

it. If necessary, hit the motor housing light-

ly with a plastic hammer for support.

Remove the bearing sleeve (3) from the

armature bearing (4).

Press off the armature bearings (4)

and (8) with aid of the forcing disks

(service tool).

Remove the insulating disk (5) and the

ring (7).

Dismantling the

spindle

Peeloffthe ring(4)and remove theplastic

housing (5).

Remove the four balls (3) with aid of a

magnet.

Loosen the five screws (1) of the adapter

sleeve (2) and remove the adapter

sleeve

(2). If necessary, use a plastic

hammer for support.

Remove the tool reception (8) completely

with the snap die (D), the spacer (7) and

the O-ring (6). Knock out the spacer (7)

through the grooves (E) with aid of a man-

drel.

Remove the snap die (D) from the tool re-

ception (8).

Remove the following parts:

grease seal (C),

spacer (B),

recoil ring (A) and

rubber ring (9).

576

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Detaching the

flange

Remove the sleeve (2), and the O-rings

(3) and 4).

Loosen the screws (1) and remove the

flange (5) with the ring (8).

Remove the spindle sleeve (7) from the

housing (6).

Detaching the

gear box cover

Lever off the O-ring (1) and the grease

seal (2) from the gear box cover (3).

Unscrew the screws (8) and loosen the

gear box cover (3) by hitting the gear box

lightly with a plastic hammer. Remove the

cover.

Remove the gasket (6) and the insert (5).

Pull out the needle bearings (4 and 7) with

aid of an interior extractor.

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Detaching the

crankshaft

Loosen the two screws (A) and remove

the service cover (8) with the gasket (B)

and the valve (9).

Remove damaged welch plug (7).

Remove the spring ring (1).

Pull off the crank wheel (2) with aid of a

pulling-off device (service tool). Steady

the crank wheel for support.

Remove the key (D) from the crank-

shaft

(5).

Removethespringring(3)andpulloutthe

crankshaft; if necessary, press out the

crankshaft through the opening in the cov-

er with aid of a suitable mandrel.

Press the ball bearing (4) off the crank-

shaft.

Remove the O-ring (6) from the gear

housing (C).

Detaching the

cylinder and the

connecting rod

1Pull the cylinder (8), the washers (3)

and 4), and the holder (5) from the

gear housing (6).

2Push the cylindrical bolt (7) from the cylin-

der (8) and pull out the connecting rod (1).

3Press the needle bearing (2) from the con-

necting rod (1).

4Pull the percussion body (A) with the gas-

ket (9) from the cylinder (8).

3 4

8A 9

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Maintenance

General It is recommended to submit the machine to maintenance after the carbon brushes have switched off.

Cleaning Clean all parts – with the exception of the electrical parts – with cold cleaning agent. Caution! No clean-

ing agent should penetrate into the bearing. Clean the electrical parts with a dry brush.

Check for wear Check the disassembled parts for wear (visual inspection) and replace worn parts.

Electrical tests Before reassembling, perform an electrical test on all relevant parts (see chapter Electrical and Me-

chanical Test Instructions).

Lubrication Each time maintenance is performed, the machine is to be lubricates as stated in the lubrication plan.

After the machine is fully disassembled, completely remove the old grease and replace with new

grease. The grease must be applied to the machine as indicated in the lubrication plan.

Legend

ACover with red grease (60 g)

BCover with blue grease (40 g)

Torques Screws in plastic 2,5 Nm

Screws in metall 4,0 Nm

(45 g)

B(30 g)

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Assembly

Mounting the

cylinder and the

connecting rod

1Press the needle bearing (2) into the con-

necting rod (1).

2Push the percussion body (A) and the

gasket (9) into the cylinder (8).

3Put together the cylinder (8) and the con-

necting rod (1) and push the cylindrical

bolt (7) through both borings.

4Insert the cylinder (8), the washers (3

and 4) and the holder (5) into the gear

housing (6).

Mounting the

crankshaft 1Insert the O-ring (6) into the gear hous-

ing (C).

2Press the ball bearing (4) onto the crank-

shaft (5).

3Insert the crankshaft (5) into the gear

housing from below (C) and fit it to the

connecting rod bearing.

4Mount the spring ring (3).

5Insert the key (D) into the crankshaft (5).

6Fit the crank wheel (2) with the collar fac-

ing the eccentric and press it on.

☞Steady the crankshaft with a suitable

mandrel which is pushed through the

opening in the cover (otherwise the

crankshaft is pushed in too far).

7Secure the crank wheel (2) with the spring

ring (1).

8If necessary, mount the welch plug (7).

9Fill the gear housing (C) through the serv-

ice opening with grease according to the

lubrication chart.

10Fit the service cover (8) with gasket (B)

and valve (9) and fasten it with the

screws (A).

3 4

8A 9

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Repair Instructions No.182.03/98

PBE 6 S

Mounting the

gear box cover 1Press the needle bearings (4 and 7) into

the gear box cover (3).

2Place the insert (5) into the gear box

cover (3) (mind the right position!) and fit

the gasket (6).

3Fitthegearbox cover (3)andfastenit with

the screws (8).

4Insert the grease seal (2) and the

O-ring (1) into the gear box cover (3).

Mounting the

flange 1Insert the spindle sleeve (7) into the hous-

ing (6).

2Fit the flange (5) with the ring (8) to the

housing (6) and fasten them with the se-

cured screws (1).

3Mount the O-rings (3 and 4) and the

sleeve (2).

Assembling the

spindle 1Insert the rubber ring (9), the recoil

ring (A), the spacer (B), and the grease

seal (C) into the flange (see assembly

step 4).

2Insert the snap die (D) into the tool recep-

tion (8).

3Insert the tool reception (8) completely

with the snap die (D), the spacer (7) and

the O-ring (6) into the gear box.

4Fittheadaptersleeve(2)andfasten it with

the secured screws (1).

5Insert the four balls (3) into the adapter

sleeve (2).

576

PAGE

Repair Instructions No.182.03/98

PBE 6 S

Mounting the

armature 1Push the insulating disk (5) and the

ring (7) over the armature shaft and press

on the armature bearings (4) and (8).

2Push the bearing sleeve (3) over the ar-

mature bearing (4).

3Lightly grease the armature bearing (8)

and insert the complete armature into the

machine by turning it.

4Insert the brush holders (C) into the motor

housing (9). Align them with the adjust-

ment tool (service tool) and fix them with

the screws (B).

5Push the field (1) into the motor hous-

ing (9) and insert the air deflector ring (2).

Mind the right position!

6Push the motor housing (9) with the

field (1) and the air deflector ring (2) over

the armature.

7Fasten the motor housing with two short

screws (A) and two long screws (D).

Assembling the

handgrip 1Insert the switch (9) with the capacitor into

the handle shell (7).

2Insert the connecting cable (H) with the

cable entry sleeve as well as the cable

clamps (D) into the handle shell (7).

3Fit the handle shell (C) with the holding-

down device to the other handle shell and

fasten them with the four screws (6).

☞Take care that no cables are jammed

or squeezed.

4Insert the handgrip holder (4) and the rub-

ber collar (3) into the handle shell (7).

5Connect according to wiring diagram.

6Insert the damping element (2) into the

housing.

7Push the completed pair of handle shells

over the housing (F) and fasten it with the

screws (G).

8Fasten both Torx screws (8) TX 30 of the

handgrip holder (4) together with the

disks.

9Insert the handle cover (A) from above

and fasten it with the screw (B).

10Screw down the handle screw (E),steady-

ing the knurled nut (5) at the same time.

A B

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